Batch Scaling Calculator

Lab to production batch scaling with mixing parameters.

Lab batch size (g)

Production batch (g)

Lab mixer diameter (cm)

Production mixer diameter (cm)

Lab mixing speed (RPM)

Lab mixing time (min)

Lab heat time (min)

Tab to move between fields

Scale factor (×)

250

Production RPM

106.7

Production batch (kg)50

Production mix time (min)57.9

Production heat time (min)396.9

Lab tip speed (m/s)1.68

Production tip speed (m/s)1.68

Power draw ratio (×)56.3

How to Use This Calculator

Enter the lab (bench-scale) batch size in grams and the target production batch size in grams.
Enter the lab and production mixer impeller diameters, along with the lab mixing speed, mixing time, and heating time.
Review the scale factor and production batch weight in kilograms.
Check the recommended production RPM, which is calculated to hold impeller tip speed constant between lab and production scale.
Use the estimated production mixing time and heating time, along with the tip speed and power draw ratio, to plan the production run.

How the result changes with Lab batch size (g)

Lab batch size (g): Weight of the lab/bench-scale batch in grams.
Production batch (g): Target production batch weight in grams.
Lab mixer diameter (cm): Diameter of lab mixer impeller in centimeters.
Production mixer diameter (cm): Diameter of production mixer impeller in centimeters.
Lab mixing speed (RPM): Lab mixer speed in revolutions per minute.
Lab mixing time (min): Total mixing time at lab scale in minutes.
Lab heat time (min): Time to heat oil/water phases at lab scale in minutes.

Scale factor (×): Multiplier from lab to production batch.
Production batch (kg): Production batch size in kilograms.
Production RPM: Recommended production mixer speed to maintain constant tip speed.
Production mix time (min): Estimated production mixing time based on diameter scaling.
Production heat time (min): Estimated production heating time based on volume scaling.
Lab tip speed (m/s): Impeller tip speed at lab scale.
Production tip speed (m/s): Impeller tip speed at production scale (should match lab).
Power draw ratio (×): Relative power requirement at production vs lab scale.

Identify Input Parameters
4 parameters
Lab batch size (g) = 200, Production batch (g) = 50000, Lab mixer diameter (cm) = 4, Production mixer diameter (cm) = 30 = 7 input(s) provided
Calculate Scale factor
Scale factor = prodBatchG / labBatchG
250 = 250
Calculate Production RPM
Production RPM = labMixSpeedRpm * (labMixerDiamCm / prodMixerDiamCm)
106.7 = 106.7
Calculate Production batch
Production batch = round((prodBatchG / 1000) * 100) / 100
50 = 50
Calculate Production mix time
Production mix time = labMixTimeMin * pow(diamRatio, 0.67)
57.9 = 57.9